Komatsu PC138E-11 Electric Hydraulic Excavator Shop Manual SEN06979-01 PDF

Description

Komatsu PC138E-11 Electric Hydraulic Excavator Shop Manual SEN06979-01 – PDF DOWNLOAD 

FILE DETAILS:

Komatsu PC138E-11 Electric Hydraulic Excavator Shop Manual SEN06979-01 – PDF DOWNLOAD 

Language : English
Pages : 2220
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu PC138E-11 Electric Hydraulic Excavator Shop Manual SEN06979-01 – PDF DOWNLOAD 

SERIAL NUMBERS 1 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 16
Foreword, Safety, Basic Information 19
How to Read the Shop Manual 19
Safety Notice for Operation 21
Precautions for Battery-Powered Hydraulic Excavator 29
Precautions to Prevent Fire 30
Prevent Fire 30
Procedures If Fire Occurs 33
Precautions When You Discard Waste Materials 34
Precautions When You Handle Hydraulic Equipment 35
Precautions When You Disconnect and Connect Pipings 38
Precautions When You Handle Electrical Equipment 44
Precautions for Maintenance of Power Electronics Components 46
Precautions Against High Voltage and High Temperature 47
Procedure for Inspection and Maintenance of Power Electronics Components 48
Precautions for Normal Inspection and Maintenance 50
Precautions When Machine Falls over and Power Electronics Components Have Damage 51
Precautions for Machine Not to be Put in Water 52
Practical Use of KOMTRAX 53
Disconnect and Connect Push-Pull Type Coupler 54
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 54
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 56
Precautions for Disconnection and Connection of Connectors 58
How to Disconnect and Connect Deutsch Connector 62
How to Disconnect and Connect Slide Lock Type Connector 63
How to Disconnect and Connect Connector with Lock to Pull 65
How to Disconnect and Connect Connector with Lock to Push 66
How to Disconnect and Connect Connector with Housing to Rotate 68
How to Disconnect and Connect High Voltage Wiring Connector of Power Electronics Components 69
How to Read the Codes for Electric Cable 73
Explanation of Terms for Maintenance Standard 77
Standard Tightening Torque Table 80
Conversion Table 85
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: PC138E-11 93
Working Range Drawings 94
Working Range Drawings: PC138E-11 94
Specifications 95
Specifications: PC138E-11 95
Weight Table 98
Weight Table: PC138E-11 98
Coolant, Lubricant 100
How to Use Coolant and Lubricants by Ambient Temperature 100
10 Structure and Function 101
Table of Contents 102
Boot-up System 105
Layout Drawing of Boot-up System 105
System Operating Lamp System 107
System Diagram of System Operating Lamp System 107
Function of Operation Lamp System 107
Operation of System Operating Lamp System 107
Auxiliary Battery Disconnect Switch 108
Function of Auxiliary Battery Disconnect Switch 108
Function of Electric Motor Shutdown Secondary Switch 109
Function of Electric Motor Shutdown Secondary Switch 109
Operation of Electric Motor Shutdown Secondary Switch 109
Electric Drive System 110
Layout Drawing of Electric Drive System 110
System Diagram of Electric Drive System 112
Structure of Electric Drive System 113
Worker Protection System When You Disassemble Power Electronics Components 114
Function of Worker Protection System When You Disassemble Power Electronics Components 114
High Voltage Wiring (Power Cable) 115
Layout Drawing of High Voltage Wiring (Power Cable) 115
Structure of High Voltage Wiring (Power Cable) 115
Function of High Voltage Wiring (Power Cable) 115
Component Parts of Electric Drive System 116
Main Battery Assembly 116
BTMS (Battery Thermal Management System) 118
Inverter 120
DC-DC Converter 122
HVJB (High Voltage Junction Box) 124
Power Distribution Unit 127
Electric Motor 130
Charging Port 132
Electric Motor System 134
Layout Drawing of Electric Motor System 134
Electric Motor Control System 135
System Diagram of Electric Motor Control System 135
Operation of Electric Motor Control System 135
Auto-Deceleration System 137
System Diagram of Auto-Deceleration System 137
Function of Auto-Deceleration System 137
Operation of Auto-Deceleration System 138
Overheat Prevention System 139
Function of Overheat Prevention System 140
Component Parts of Electric Motor System 142
Coupling 142
Cooling System 143
Layout Drawing of Cooling System 143
Specifications of Cooling System 145
Fan Speed Control System of Electric Fan 146
Function of Fan Speed Control System of Electric Fan 146
Component Parts of Cooling System 147
Electric Fan 147
Control System 148
Layout Drawing of Control System 148
Machine Monitor System 149
System Diagram of Machine Monitor System 149
Function of Machine Monitor System 150
KomVision System 151
Layout Drawing of KomVision System 151
System Diagram of KomVision System 153
Function of KomVision System 153
KOMTRAX System 155
System Diagram of KOMTRAX System 155
Function of KOMTRAX System 155
Component Parts of Control System 156
Machine Monitor 156
KomVision Controller 169
KomVision Camera 173
Gateway Function Controller 174
Communication Terminal 177
Pump Controller 178
Resistor for PC-EPC Valve 182
CAN Terminating Resistor 183
Power Management Controller 184
Battery Integration Controller 188
Telemetry (Battery Information Communication Terminal) 192
Electric Fan Controller 194
Motor Speed Adjustment Dial 195
Hydraulic System 197
Layout Drawing of Hydraulic System 197
CLSS 199
Structure of CLSS 199
Function of CLSS 200
Electric Motor and Pump Combined Control System 202
System Diagram of Electric Motor and Pump Combined Control System 202
Function of Electric Motor and Pump Combined Control System 203
Component Parts of Hydraulic System 207
Hydraulic Tank 207
Main Pump 209
Control Valve 237
Work Equipment System 296
Layout Drawing of Work Equipment System 296
Structure of Valve Control 299
PPC Lock System 300
System Diagram of PPC Lock 300
Function of PPC Lock System 300
Work Equipment and Travel Automatic Lock System 301
System Diagram of Lock Lever Automatic Lock System 301
Function of Work Equipment and Travel Automatic Lock System 301
Operation of Lock Lever Automatic Lock System 302
Attachment Oil Flow Adjuster System 303
Attachment Oil Flow Adjuster System Diagram 303
Function of Attachment Oil Flow Adjuster System 304
Component Parts of Work Equipment System 305
Work Equipment and Swing PPC Valve 305
1st-Line Attachment PPC Valve (with EPC Valve) 310
Blade PPC Valve 318
Solenoid Valve 320
Variable Back Pressure Solenoid Valve 323
Arm Dump Quick Return Valve 324
Pilot Circuit Accumulator 326
Attachment Circuit Accumulator (For Low Pressure Circuit) 327
Swing System 328
Layout Drawing of Swing System 328
Swing Control System Diagram 330
Function of Swing Control System 331
Component Parts of Swing System 333
Swing Motor 333
Swing Machinery 343
Swing Circle 345
Travel System 346
Layout Drawing of Travel System 346
System Diagram of Travel Control System 348
Function of Travel Control System 349
Component Parts of Travel System 352
Travel Motor 352
Travel PPC Valve 362
Center Swivel Joint 366
Undercarriage and Frame 368
Layout Drawing of Undercarriage 368
Specifications of Undercarriage 368
Idler Cushion 369
Structure of Idler Cushion 369
Specifications of Idler Cushion 369
Work Equipment 370
Structure of Work Equipment 370
Function of Work Equipment 371
Work Equipment Clearance Adjustment Shim 372
Function of Work Equipment Clearance Adjustment Shim 372
Bucket Clearance Adjustment Shim 373
Function of Bucket Clearance Adjustment Shim 373
CAB Related Parts 374
ROPS CAB 374
Structure of ROPS CAB 374
Function of ROPS CAB 374
CAB Mount 375
Structure of CAB Mount 375
Function of CAB Mount 375
Remove Wiring Harness Out of Cab 377
20 Standard Value Table 379
Table of Contents 380
Standard Value Table for Electric Motor 381
Standard Value Table for Electric Motor: PC138E-11 381
Standard Value Table for Machine 382
Standard Value Table for Machine: PC138E-11 382
Machine Posture and Procedures to Measure Performance 394
30 Testing and Adjusting 397
Table of Contents 398
Precautions Before Work 401
Related Information on Testing and Adjusting 402
Differences In Machine Monitor Symbols 402
Tools for Testing and Adjusting 403
Sketch of Tools for Testing and Adjusting 408
Motor and Cooling System 409
Examine Electric Motor Speed 409
How to Examine Electric Motor Speed 409
Examine and Adjust Air Conditioner Compressor Belt Tension 413
How to Examine Air Conditioner Compressor Belt 413
How to Adjust Air Conditioner Compressor Belt 413
Electric Drive System 415
Precautions for Electric Drive System 415
Replace Desiccant for Main Battery 416
How to Replace Desiccant for Main Battery 416
Bleed Air from Coolant Circuit of Main Battery 420
How to Bleed Air from Coolant Circuit of Main Battery 420
Examine Water Level of Hot Water Heater and Add Water 422
How to Examine Water Level of Hot Water Heater and Add Water 422
Bleed Air from Water Circuit of Hot Water Heater 424
How to Bleed Air from Water Circuit of Hot Water Heater 424
Power Train 426
Examine Swing Circle Bearing Clearance 426
How to Examine Swing Circle Bearing Clearance 426
Undercarriage and Frame 427
Examine and Adjust Track Tension 427
How to Examine Track Tension 427
How to Adjust Track Tension 427
Hydraulic System 429
Release Remained Pressure in Hydraulic Circuit 429
How to Release Remained Pressure from Hydraulic Tank 429
How to Release Remained Pressure in Hydraulic Cylinder Circuit 429
How to Release Remained Pressure from Swing Motor Circuit 430
How to Release Remained Pressure from Travel Motor Circuit 431
Examine and Adjust Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits 432
How to Examine Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits 432
How to Adjust Oil Pressure in Work Equipment, Swing, Travel, and Blade Circuits 443
Examine Oil Pressure of Control Circuit 445
How to Examine Oil Pressure in Control Circuit 445
Examine and Adjust Oil Pressure in Pump PC Control Circuit 447
How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) 447
How to Examine PC-EPC Valve Outlet Pressure 449
How to Adjust Oil Pressure in Pump PC Control Circuit 450
Examine and Adjust Oil Pressure in Pump LS Control Circuit 452
How to Examine LS Differential Pressure with Machine Monitor 452
How to Examine LS Differential Pressure by Testing Tool 454
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 457
How to Adjust LS Valve 459
Examine Outlet Pressure of Solenoid Valve 460
How to Examine Outlet Pressure of Solenoid Valve 460
Operating Condition of Solenoid Valve 462
How to Examine Outlet Pressure in Variable Back Pressure Solenoid Valve 463
Operating Condition of Variable Back Pressure Solenoid Valve 464
Examine PPC Valve Outlet Pressure 465
How to Examine Outlet Pressure in PPC Valve 465
Examine Attachment Circuit Oil Pressure 468
How to Examine Attachment Circuit Oil Pressure 468
Adjust Play of Work Equipment and Swing PPC Valves 469
How to Adjust Play of Work Equipment and Swing PPC Valves 469
Examine and Adjust Travel Deviation 470
How to Examine Travel Deviation 470
How to Adjust Travel Deviation 471
Examine Parts Which Cause Hydraulic Drift of Work Equipment 473
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 473
How to Examine Parts Which Cause Hydraulic Drift of Arm Cylinder 474
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 474
Examine Oil Leakage 475
How to Examine Oil Leakage from Boom Cylinder 475
How to Examine Oil Leakage from Arm Cylinder 476
How to Examine Oil Leakage from Bucket Cylinder 476
How to Examine Oil Leakage from Blade Cylinder 477
How to Examine Oil Leakage from Swing Motor 478
How to Examine Oil Leakage from Travel Motor 479
Bleed Air from Hydraulic System 481
How to Bleed Air from Hydraulic System 482
Examine and Charge Accumulator (Made by Eagle Industry Co , Ltd ) Nitrogen Gas Pressure for Attachment 486
How to Examine Accumulator (Made by Eagle Industry Co , Ltd ) Nitrogen Gas Pressure for Attachment 486
CAB Related Parts 490
Examine CAB Tipping Stopper 490
How to Examine Cab Tipping Stopper 490
Adjust Mirrors 491
How to Adjust Machine Left Front Mirror (A) 491
Adjust Machine Rear Mirror (B) 492
How to Examine and Adjust Slide Door 493
How to Examine and Adjust Slide Door When It is Closed and Locked 493
How to Examine and Adjust Slide Door When It is Open and Locked 505
Electrical System 518
Set and Operate Machine Monitor 518
Operator Mode 522
Function to Show Technician Identification Status Screen 522
Function to Show Operator Identification Input Screen 522
Examine Function by LCD (Liquid Crystal Display) 523
Examine Function of Service Meter 523
Usage Limitation and Maintenance Password Change Function 524
Service Mode 527
How to Operate Service Mode 527
How to See Pre-defined Monitoring Information 530
How to Examine Monitoring Information 533
Abnormality Record Menu 541
How to See Maintenance Record 546
Maintenance Mode Setting 547
How to Set Phone Number Entry 551
Default Setting Menu 552
Testing Menu 565
Adjustment Menu 566
KOMTRAX Settings Menu 593
How to Show Service Message 595
How to Start Up KOMTRAX System 597
How to Stop Use of KOMTRAX System 602
Adjust KomVision Camera Angle 604
How to Adjust KomVision Camera Angle 605
Adjust KomVision Related Function 607
Setting of KomVision (Main Setting) 608
Setting of KomVision (Camera Setting) 611
Setting of KomVision (Camera Calibration) 613
Set Region of Bluetooth(R) Compatible Radio 626
How to Set Region of Bluetooth(R) Compatible Radio 626
Handle Voltage Circuit of Power Management Controller 628
Handle Auxiliary Battery Disconnect Switch 629
Handle MSD of High Voltage Junction Box 630
Handle MSD of Main Battery 631
Examine Diodes 632
How to Examine Diodes by Digital Tester 632
How to Examine Diodes by Analog Tester 632
Pm Clinic 633
Pm Clinic Service 633
Pm Clinic Check Sheet: PC138E-11 635
40 Troubleshooting 643
Table of Contents 644
Precautions Before Work 649
Related Information to Troubleshooting 650
General Troubleshooting Points 650
Sequence of Events in Troubleshooting 651
Checks Before Troubleshooting 653
Inspection Procedure Before Troubleshooting 655
Walk-Around Check 655
Test in Accordance with Testing Procedure 656
See Main Battery Level 656
See Heating Water Level 656
Examine Hydraulic Oil Level 657
Examine Hydraulic Oil Strainer 659
Examine Hydraulic Oil Filter 660
Examine Oil Level in Swing Machinery Case 661
Examine Oil Level in Final Drive Case 662
Bleed Air from Hydraulic System 662
How to Examine Electric Equipment 662
Preparation for Troubleshooting of Electrical System 667
Preparation for Troubleshooting of Machine Monitor 667
Preparation for Troubleshooting of Pump Controller 667
Preparation for Troubleshooting of Gateway Function Controller 668
How to Disconnect and Connect Connector with a Special Lock 669
Procedure for Troubleshooting 673
Symptom and Troubleshooting Numbers 676
Information Shown in Troubleshooting Table 679
Connector List and Layout 681
Connector Layout (1) 689
Connector Layout (2) 691
Connector Layout (3) 693
Connector Layout (4) 695
Connector Contact Connection Table 696
T-Branch Box and T-Branch Adapter Table 736
Fuse Location Table 742
Failure Code Table 745
Troubleshooting by Failure Code (Display of Code) 764
Failure Code [6AZ0ZG] 764
Failure Code [879AKA] 766
Failure Code [879AKB] 768
Failure Code [879BKA] 770
Failure Code [879BKB] 772
Failure Code [879CKA] 774
Failure Code [879CKB] 775
Failure Code [879DKZ] 776
Failure Code [879EMC] 779
Failure Code [879FMC] 780
Failure Code [879GKX] 781
Failure Code [989L00] 783
Failure Code [989M00] 784
Failure Code [989N00] 785
Failure Code [B@HANS] 786
Failure Code [D110KB] 788
Failure Code [D19JKZ] 790
Failure Code [D811MC] 793
Failure Code [D862KA] 794
Failure Code [D8ALKA] 796
Failure Code [D8ALKB] 799
Failure Code [D8AQKR] 801
Failure Code [D8G1KT] 807
Failure Code [D8G6KT] 808
Failure Code [DA20MC] 809
Failure Code [DA22KK] 810
Failure Code [DA22KT] 814
Failure Code [DA25KP] 817
Failure Code [DA26KP] 822
Failure Code [DA29KQ] 825
Failure Code [DA2JKT] 828
Failure Code [DA2JKY] 829
Failure Code [DA2LKA] 830
Failure Code [DA2LKB] 833
Failure Code [DA2QKR] 835
Failure Code [DA2RKR] 842
Failure Code [DAF0KM] 849
Failure Code [DAF0MB] 850
Failure Code [DAF0MC] 851
Failure Code [DAF9KQ] 852
Failure Code [DAFGMC] 854
Failure Code [DAFLKA] 855
Failure Code [DAFLKB] 858
Failure Code [DAFQKR] 860
Failure Code [DAZ9KQ] 866
Failure Code [DAZQKR] 868
Failure Code [DBP0KM] 873
Failure Code [DBP0KT] 874
Failure Code [DBP5KB] 875
Failure Code [DBP5KY] 878
Failure Code [DBPQKR] 881
Failure Code [DDNRKA] 887
Failure Code [DDNRKY] 890
Failure Code [DDNS00] 893
Failure Code [DFB1KZ] 896
Failure Code [DFB2KZ] 899
Failure Code [DFB3L8] 902
Failure Code [DFB4L8] 904
Failure Code [DFB5KZ] 906
Failure Code [DFB6KZ] 909
Failure Code [DGH2KA] 912
Failure Code [DGH2KB] 914
Failure Code [DHPAMA] 916
Failure Code [DHS3MA] 919
Failure Code [DHS4MA] 922
Failure Code [DHS8MA] 925
Failure Code [DHS9MA] 928
Failure Code [DHSAMA] 931
Failure Code [DHSBMA] 934
Failure Code [DHSCMA] 937
Failure Code [DHSDMA] 940
Failure Code [DHSFMA] 943
Failure Code [DHSGMA] 946
Failure Code [DHSHMA] 949
Failure Code [DHSJMA] 952
Failure Code [DHSKMA] 955
Failure Code [DHSLMA] 957
Failure Code [DHX1MA] 959
Failure Code [DKULKA] 960
Failure Code [DKULKB] 962
Failure Code [DKULKY] 965
Failure Code [DR10KA] 967
Failure Code [DR12KA] 972
Failure Code [DR20KA] 974
Failure Code [DR21KX] 976
Failure Code [DR30KA] 977
Failure Code [DR31KX] 979
Failure Code [DR40KA] 980
Failure Code [DUMBKA] 982
Failure Code [DUMBKB] 985
Failure Code [DV20KB] 987
Failure Code [DW43KA] 989
Failure Code [DW43KB] 991
Failure Code [DW43KY] 993
Failure Code [DW45KA] 995
Failure Code [DW45KB] 999
Failure Code [DW45KY] 1003
Failure Code [DW4CKY] 1005
Failure Code [DW91KA] 1007
Failure Code [DW91KB] 1009
Failure Code [DW91KY] 1011
Failure Code [DWA2KA] 1013
Failure Code [DWA2KB] 1015
Failure Code [DWA2KY] 1017
Failure Code [DWJ0KA] 1019
Failure Code [DWJ0KB] 1021
Failure Code [DWJ0KY] 1023
Failure Code [DWK2KA] 1025
Failure Code [DWK2KB] 1027
Failure Code [DWK2KY] 1029
Failure Code [DWNSKA] 1031
Failure Code [DWNSKB] 1033
Failure Code [DWNSKY] 1035
Failure Code [DXA8KA] 1037
Failure Code [DXA8KB] 1041
Failure Code [DXE4KA] 1044
Failure Code [DXE4KB] 1046
Failure Code [DXE4KY] 1048
Failure Code [DXE7KA] 1050
Failure Code [DXE7KB] 1052
Failure Code [DXE7KY] 1054
Failure Code [DXE8KA] 1056
Failure Code [DXE8KB] 1058
Failure Code [DXE8KY] 1060
Failure Code [DXE9KA] 1062
Failure Code [DXE9KB] 1064
Failure Code [DXE9KY] 1066
Failure Code [DXEAKA] 1068
Failure Code [DXEAKB] 1070
Failure Code [DXEAKY] 1072
Failure Code [DY20KA] 1074
Failure Code [DY20MA] 1077
Failure Code [DY2CKB] 1080
Failure Code [DY2DKB] 1084
Failure Code [DY2EKB] 1087
Failure Code [F311KA] 1090
Failure Code [F311KB] 1092
Failure Code [F312KA] 1094
Failure Code [F312KB] 1096
Failure Code [F313KA] 1098
Failure Code [F313KB] 1100
Failure Code [F314KA] 1102
Failure Code [F314KB] 1104
Failure Code [F316KB] 1106
Failure Code [F316KY] 1108
Failure Code [F318KB] 1110
Failure Code [F318KY] 1112
Failure Code [F31AKB] 1114
Failure Code [F31AKY] 1116
Failure Code [F31BKB] 1118
Failure Code [F31BKY] 1120
Failure Code [F31CKB] 1122
Failure Code [F31CKY] 1124
Failure Code [F31DKB] 1126
Failure Code [F31DKY] 1128
Failure Code [F31EKB] 1130
Failure Code [F31EKY] 1132
Troubleshooting of Electrical System (E-Mode) 1134
Electric Motor Does Not Start (Electric Motor Does Not Run) 1134
When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1139
Hydraulic Oil Temperature Monitor Comes On in White While Electric Motor Runs 1142
Temperature Monitor of Power Electronics Components Comes On in Red While Electric Motor Runs 1143
Hydraulic Oil Temperature Monitor Comes On in Red While Electric Motor Runs 1144
Temperature Gauge of Power Electronics Components Does Not Move from Minimum or Maximum 1145
Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum 1146
Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 1148
Some Areas of Machine Monitor Screen are Not Shown 1149
Function Switch Does Not Operate 1150
Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated 1151
Auto-Decelerator is Not Operated or Canceled with Lever 1152
Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated 1154
When Working Mode is Changed, Setting of Electric Motor and Hydraulic Pump is Not Changed 1155
Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated 1156
Travel Speed Does Not Change Even When You Change Travel Speed 1157
Alarm Buzzer Does Not Stop 1158
Service Meter is Not Shown While Starting Switch is in OFF Position 1159
Service Mode Cannot be Selected 1160
All Work Equipment, Swing, Travel Do Not Operate 1161
All Work Equipment, Swing, Travel Cannot be Locked 1164
Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position 1166
While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated 1168
Work Equipment Does Not Operate While Lock Lever Automatic Release Switch is in Release Position 1170
Travel Alarm Does Not Operate During Travel 1172
Travel Alarm Does Not Stop When Machine Stops 1174
Horn Does Not Sound 1175
Horn Does Not Stop 1177
Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated 1178
Windshield Wiper Does Not Operate When Wiper Switch is Operated 1179
When Window Washer Switch is Operated, Window Washer Does Not Operate 1181
“Boom Raise” is Not Shown Correctly with Monitoring Function 1182
“Boom Lower” is Not Shown Correctly with Monitoring Function 1183
“Arm OUT” is Not Shown Correctly with Monitoring Function 1184
“Arm IN” is Not Shown Correctly with Monitoring Function 1185
Bucket DUMP is Not Shown Correctly with Monitoring Function 1186
Bucket CURL is Not Shown Correctly with Monitoring Function 1187
Swing is Not Shown Correctly with Monitoring Function 1188
Travel is Not Shown Correctly with Monitoring Function 1189
Service is Not Shown Correctly with Monitoring Function 1190
Blade RAISE is Not Shown Correctly with Monitoring Function 1193
Blade LOWER is Not Shown Correctly with Monitoring Function 1194
KOMTRAX System Does Not Operate Correctly 1195
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1196
Information Shown in Troubleshooting Table (H-Mode) 1196
Failure Mode and Cause Table 1197
All Work Equipment, Swing and Travel Do Not Work 1205
All Work Equipment, Swing, and Travel Lack Speed or Power 1206
Fine Control Performance or Response is Unsatisfactory 1208
Unusual Noise is Heard from Around Hydraulic Pump 1209
Electric Motor Speed Decreases Largely or Electric Motor Stops 1210
Boom Speed or Power is Low 1212
Arm Speed or Power is Low 1215
Bucket Speed or Power is Low 1218
Blade Speed or Power is Low 1221
Work Equipment Does Not Move in Single Operation 1223
Hydraulic Drift of Boom is Large 1224
Hydraulic Drift of Arm is Large 1225
Hydraulic Drift of Bucket is Large 1226
Hydraulic Drift of Blade is Large 1227
When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 1229
Time Lag of Work Equipment is Large 1230
Attachment Circuit Cannot be Changed 1231
Oil Flow in Attachment Circuit Cannot be Changed 1232
In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 1233
In Mixed Operation of Swing and Travel, Travel Speed Falls Largely 1234
In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low 1235
Machine Does Not Travel Straight 1236
Machine is Not Steered Well or Steering Power is Low 1239
Travel Speed is Low 1241
One of Tracks Does Not Run 1243
Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 1245
Upper Structure Does Not Swing in Two Directions of Right and Left 1246
Machine Swings Only in One Direction 1247
Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left 1248
Swing Acceleration or Swing Speed is Low in Only One Direction 1249
Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 1250
Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 1251
Shock is Large When Upper Structure Stops Swing Operation 1252
Large Unusual Noise is Made When Upper Structure Stops Swing Operation 1253
Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 1254
Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 1255
50 Disassembly and Assembly 1257
Table of Contents 1258
Precautions Before Work 1262
Related Information on Disassembly and Assembly 1263
How to Read This Manual 1263
Coating Materials List 1264
Special Tool List 1269
Sketches of Special Tools 1283
Prepare 1284
Drain and Add Coolant 1284
How to Drain Coolant 1284
How to Add Coolant 1286
Drain and Add Hydraulic Oil 1289
How to Drain Hydraulic Oil 1289
How to Add Hydraulic Oil 1290
Collect and Refill Refrigerant 1292
How to Collect Refrigerant 1292
How to Refill Refrigerant 1293
Electric Motor and Cooling System 1295
Remove and Install Air Conditioner Compressor Belt 1295
How to Remove Air Conditioner Compressor Belt 1295
How to Install Air Conditioner Compressor Belt 1297
Remove and Install Hydraulic Oil Cooler Assembly 1299
How to Remove Hydraulic Oil Cooler Assembly 1299
How to Install Hydraulic Oil Cooler Assembly 1303
Remove and Install Hood Assembly 1307
How to Remove Hood Assembly 1307
How to Install Hood Assembly 1312
Remove and Install Air Conditioner Compressor Assembly 1317
How to Remove Air Conditioner Compressor Assembly 1317
How to Install Air Conditioner Compressor Assembly 1318
Remove and Install Air Conditioner Condenser Assembly 1320
How to Remove Air Conditioner Condenser Assembly 1320
How to Install Air Conditioner Condenser Assembly 1324
Remove and Install Electric Fan Assembly 1328
How to Remove Electric Fan Assembly 1328
How to Install Electric Fan Assembly 1330
Remove and Install BTMS 1332
How to Remove BTMS 1332
How to Install BTMS 1335
Power Train 1340
Remove and Install Travel Motor and Final Drive Assembly 1340
How to Remove Travel Motor and Final Drive Assembly 1341
How to Install Travel Motor and Final Drive Assembly 1344
Disassemble and Assemble Travel Motor and Final Drive Assembly 1347
How to Disassemble Travel Motor and Final Drive Assembly 1358
How to Assemble Travel Motor and Final Drive Assembly 1376
Remove and Install Swing Motor and Swing Machinery Assembly 1396
How to Remove Swing Motor and Swing Machinery Assembly 1396
How to Install Swing Motor and Swing Machinery Assembly 1399
Disassemble and Assemble Swing Machinery Assembly 1402
How to Disassemble Swing Machinery Assembly 1402
How to Assemble Swing Machinery Assembly 1405
Remove and Install Swing Circle Assembly 1412
How to Remove Swing Circle Assembly 1412
How to Install Swing Circle Assembly 1413
Undercarriage and Frame 1414
Separate and Connect Track Assembly 1414
How to Separate Track Assembly 1415
How to Install Track Assembly 1416
Remove and Install Sprocket 1419
How to Remove Sprocket 1419
How to Install Sprocket 1420
Remove and Install Idler and Idler Cushion Assembly 1421
How to Remove Idler and Idler Cushion Assembly 1421
How to Install Idler and Idler Cushion Assembly 1422
Disassemble and Assemble Idler Assembly 1423
How to Disassemble Idler Assembly 1423
How to Assemble Idler Assembly 1424
Disassemble and Assemble Idler Cushion Assembly 1428
How to Disassemble Idler Cushion Assembly 1428
How to Assemble Idler Cushion Assembly 1430
Disassemble and Assemble Track Roller Assembly 1433
How to Disassemble Track Roller Assembly 1433
How to Assemble Track Roller Assembly 1435
Remove and Install Revolving Frame Assembly 1438
How to Remove Revolving Frame Assembly 1439
How to Install Revolving Frame Assembly 1442
Remove and Install Counterweight Assembly 1445
How to Remove Counterweight Assembly 1445
How to Install Counterweight Assembly 1447
Hydraulic System 1449
Remove and Install Center Swivel Joint Assembly 1449
How to Remove Center Swivel Joint Assembly 1450
How to Install Center Swivel Joint Assembly 1455
Disassemble and Assemble Center Swivel Joint Assembly 1460
How to Disassemble Center Swivel Joint Assembly 1460
How to Assemble Center Swivel Joint Assembly 1461
Remove and Install Hydraulic Tank Assembly 1462
How to Remove Hydraulic Tank Assembly 1463
How to Install Hydraulic Tank Assembly 1473
Remove and Install Main Pump Assembly 1485
How to Remove Main Pump Assembly 1485
How to Install Main Pump Assembly 1489
Remove and Install Control Valve Assembly 1494
How to Remove Control Valve Assembly 1495
How to Install Control Valve Assembly 1513
Disassemble and Assemble Control Valve Assembly 1532
How to Assemble Control Valve Assembly 1532
How to Replace Pressure Reducing Valve Cartridge Assembly 1535
Disassemble and Assemble Work Equipment PPC Valve Assembly 1538
How to Disassemble Work Equipment PPC Valve Assembly 1538
How to Assemble Work Equipment PPC Valve Assembly 1539
Disassemble and Assemble Travel PPC Valve Assembly 1541
How to Disassemble Travel PPC Valve Assembly 1541
How to Assemble Travel PPC Valve Assembly 1541
Work Equipment 1543
Remove and Install Blade Assembly 1543
How to Remove Blade Assembly 1543
How to Install Blade Assembly 1544
Remove and Install Work Equipment Assembly 1547
How to Remove Work Equipment Assembly 1548
How to Install Work Equipment Assembly 1555
Remove and Install Boom Anti-Drop Valve Assembly 1563
How to Remove Boom Anti-Drop Valve Assembly 1563
How to Install Boom Anti-Drop Valve Assembly 1566
Remove and Install Arm Anti-Drop Valve Assembly 1568
How to Remove Arm Anti-Drop Valve Assembly 1568
How to Install Arm Anti-Drop Valve Assembly 1571
Disassemble and Assemble Anti-Drop Valve Assembly 1573
How to Disassemble Anti-Drop Valve Assembly 1573
How to Assemble Anti-Drop Valve Assembly 1573
Disassemble and Assemble Work Equipment Cylinder Assembly 1574
How to Disassemble Work Equipment Cylinder Assembly 1575
How to Assemble Work Equipment Cylinder Assembly 1577
CAB Related Parts 1584
Remove and Install Operator Cab Assembly 1584
How to Remove Operator Cab Assembly 1584
How to Install Operator Cab Assembly 1595
Remove and Install Operator Cab Door 1607
How to Install Operator Cab Door 1608
Remove and Install Operator Cab Glass (Adhered Glass) 1612
How to Remove Operator Cab Glass (Adhered Glass) 1613
How to Install Operator Cab Glass (Adhered Glass) 1614
Remove and Install Front Window Assembly 1623
How to Remove Front Window Assembly 1623
How to Install Front Window Assembly 1626
Remove and Install Floor Frame Assembly 1627
How to Remove Floor Frame Assembly 1628
How to Install Floor Frame Assembly 1642
Remove and Install Air Conditioner Unit Assembly 1657
How to Remove Air Conditioner Unit Assembly 1657
How to Install Air Conditioner Unit Assembly 1672
Remove and Install Operator Seat 1688
How to Remove Operator Seat 1688
How to Install Operator Seat 1692
Remove and Install Seat Belt 1695
How to Remove Seat Belt 1695
How to Install Seatbelt 1697
Remove and Install Work Equipment Control Lever Assembly 1698
How to Remove Work Equipment Control Lever Assembly 1698
How to Install Work Equipment Control Lever Assembly 1704
Remove and Install Front Wiper Assembly 1712
How to Remove Front Wiper Assembly 1712
How to Install Front Wiper Assembly 1717
Remove and Install Lower Wiper Assembly 1725
How to Remove Lower Wiper Assembly 1725
How to Install Lower Wiper Assembly 1727
Remove and Install Hot Water Heater Assembly 1730
How to Remove Hot Water Heater Assembly 1730
How to Install Hot Water Heater Assembly 1733
Electrical System 1737
Remove and Install Pump Controller Assembly 1737
How to Remove Pump Controller Assembly 1737
How to Install Pump Controller Assembly 1743
Remove and Install KomVision Controller Assembly 1749
How to Remove KomVision Controller Assembly 1749
How to Install KomVision Controller Assembly 1753
Remove and Install Machine Monitor Assembly 1757
How to Remove Machine Monitor Assembly 1757
How to Install Machine Monitor Assembly 1760
Remove and Install KomVision Camera 1764
How to Remove KomVision Camera 1764
How to Install KomVision Camera 1768
Remove and Install Gateway Function Controller Assembly 1773
How to Remove Gateway Function Controller Assembly 1773
How to Install Gateway Function Controller Assembly 1779
Remove and Install Communication Terminal Wiring Harness 1785
How to Remove Communication Terminal Wiring Harness 1785
How to Install Communication Terminal Wiring Harness 1795
Remove and Install Communication Terminal 1805
How to Remove Communication Terminal 1805
How to Install Communication Terminal 1806
Remove and Install Power Management Controller Assembly 1808
How to Remove Power Management Controller Assembly 1808
How to Install Power Management Controller Assembly 1809
Remove and Install Electric Motor Assembly 1811
How to Remove Electric Motor Assembly 1812
How to Install Electric Motor Assembly 1824
Remove and Install Main Battery MSD 1837
How to Remove Main Battery MSD 1837
How to Install Main Battery MSD 1840
Remove and Install Main Battery 1844
How to Remove Main Battery 1844
How to Install Main Battery 1877
Remove and Install Desiccant for Main Battery 1912
How to Remove Desiccant for Main Battery 1912
How to Install Desiccant for Main Battery 1923
Remove and Install Inverter 1937
How to Remove Inverter 1938
How to Install Inverter 1941
Remove and Install HVJB 1945
How to Remove HVJB 1945
How to Install HVJB 1948
Remove and Install Power Distribution Unit 1952
How to Remove Power Distribution Unit 1952
How to Install Power Distribution Unit 1958
Remove and Install DC-DC Converter 1964
Remove DC-DC Converter 1964
Install DC-DC Converter 1967
Remove and Install Charging Port 1971
How to Remove Charging Port 1971
How to Install Charging Port 1974
Remove and Install Telemetry 1977
How to Remove Telemetry 1977
How to Install Telemetry 1979
Remove and Install Main Battery Integration Controller 1980
How to Remove Main Battery Integration Controller 1980
How to Install Main Battery Integration Controller 1981
60 Maintenance Standard 1983
Table of Contents 1984
Explanation of Terms for Maintenance Standard 1986
Electric Motor and Cooling System 1988
Maintenance Standard for Electric Motor 1988
Maintenance Standard for Electric Motor Terminal 1989
Maintenance Standard for Inverter Mount 1990
Maintenance Standard for Cooling System 1991
Maintenance Standard for Main Battery 1992
Maintenance Standard for BTMS 1993
Maintenance Standard for Coupling 1994
Electric Devices 1995
Maintenance Standard for HVJB Mount 1995
Maintenance Standard for DC-DC Converter Mount 1996
Maintenance Standard for Power Distribution Unit Mount 1997
Maintenance Standard for Charging Port Mount 1998
Maintenance Standard for Heater 1999
Power Train 2000
Maintenance Standard for Swing Circle 2000
Maintenance Standard for Swing Machinery 2001
Maintenance Standard for Sprocket 2003
Undercarriage and Frame 2004
Maintenance Standard for Track Frame and Idler Cushion 2004
Maintenance Standard for Idler 2006
Maintenance Standard for Track Roller 2007
Maintenance Standard for Carrier Roller 2008
Maintenance Standard for Track Shoes 2009
Maintenance Standard for Triple Shoes 2012
Maintenance Standard for Road Liner 2013
Hydraulic System 2014
Maintenance Standard for Hydraulic Tank 2014
Maintenance Standard for Main Pump 2015
Maintenance Standard for PC-EPC Valve 2019
Maintenance Standard for Swing Motor 2020
Maintenance Standard for Travel Motor 2023
Maintenance Standard for Control Valve 2024
Maintenance Standard for Boom Anti-Drop Valve 2036
Maintenance Standard for Arm Anti-Drop Valve 2038
Maintenance Standard for Work Equipment and Swing PPC Valve 2040
Maintenance Standard for Blade PPC Valve 2043
Maintenance Standard for Travel PPC Valve 2045
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2048
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2050
Maintenance Standard for Solenoid Valve 2051
Maintenance Standard for Variable Back Pressure Solenoid Valve 2053
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 2054
Maintenance Standard for Attachment Circuit Accumulator (For Low Pressure Circuit) 2055
Maintenance Standard for Arm OUT Quick Return Valve 2056
Maintenance Standard for Center Swivel Joint 2057
Work Equipment 2058
Maintenance Standard for Work Equipment Linkage 2058
Dimensions of Arm 2063
Dimensions of Bucket 2065
Maintenance Standard for Boom Cylinder 2067
Maintenance Standard for Arm Cylinder 2068
Maintenance Standard for Bucket Cylinder 2069
Maintenance Standard for Blade Cylinder 2070
CAB Related Parts 2071
Maintenance Standard for CAB Mount 2071
80 Appendix 2073
Table of Contents 2074
Precautions Before Work 2076
Air Conditioner System 2077
Precautions for Refrigerant 2077
Air Conditioner Component 2078
Specifications of Air Conditioner 2080
Structure and Function of Refrigeration Cycle 2081
Outline of Refrigeration Cycle 2082
Component Parts of Air Conditioner System 2084
Air Conditioner Unit 2084
Configuration Diagram of Air Conditioner Unit 2084
Function of Air Conditioner Unit 2086
Component Parts of Air Conditioner Unit 2087
Function of Evaporator as Air Conditioner Unit Component 2087
Function of Heater Core as Air Conditioner Unit Component 2087
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2087
Function of Servo Motor as Air Conditioner Unit Component 2087
Structure of Expansion Valve as Air Conditioner Unit Component 2088
Function of Expansion Valve as Air Conditioner Unit Component 2088
Operate Expansion Valve as Air Conditioner Unit Component 2088
Function of Dual Pressure Switch 2089
Air Conditioner Controller 2090
Structure of Air Conditioner Controller 2090
Compressor 2091
Structure of Compressor 2091
Specifications of Compressor 2091
Function of Compressor 2091
Condenser 2092
Structure of Condenser 2092
Specifications of Condenser 2092
Function of Condenser 2092
Air Conditioner Related Sensors 2094
Structure of Sunlight Sensor 2094
Function of Sunlight Sensor 2094
Structure of Outside Temperature Sensor 2094
Function of Outside Air Temperature Sensor 2094
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2096
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 2098
System Diagram of Air Conditioner 2100
Input and Output Signals of Air Conditioner Controller 2101
Function of Air Conditioner Controller 2102
Locations of Air Conditioner Parts and Layout of Connectors 2103
Examine Air Leakage (Duct) 2112
How to Examine Air Leakage (Duct) 2112
Examine Air Conditioner with Self-Diagnosis Function 2114
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2115
Examine Vent (Mode) Changeover 2117
How to Examine Vent (Mode) Changeover 2117
Examine Fresh/Recirc Air Changeover 2118
How to Examine Fresh/Recirc Air Changeover 2118
Examine Sunlight Sensor 2119
How to Examine Sunlight Sensor 2119
Examine Refrigerant (Dual) Pressure Switch 2120
How to Examine Refrigerant (Dual) Pressure Switch 2120
Examine Relay 2122
How to Examine Relay 2122
Air Conditioner Troubleshooting Chart 1 2123
Air Conditioner Troubleshooting Chart 2 2124
Information Shown in Troubleshooting Table 2126
Failure Code [879AKA] 2127
Failure Code [879AKB] 2129
Failure Code [879BKA] 2131
Failure Code [879BKB] 2133
Failure Code [879CKA] 2135
Failure Code [879CKB] 2136
Failure Code [879DKZ] 2137
Failure Code [879EMC] 2140
Failure Code [879FMC] 2141
Failure Code [879GKX] 2142
Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 2144
Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2146
Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 2149
Troubleshooting for Fresh/Recirc Air Changeover 2151
Troubleshooting by Gauge Pressure 2153
Connect Service Tool 2155
How to Connect Service Tool 2155
Precautions for Disconnection and Connection of Air Conditioner Piping 2157
Handle Compressor Oil 2159
How to Replace Desiccant 2161
90 Circuit Diagrams 2163
Table of Contents 2164
How to Read the Codes for Electric Cable 2165
Hydraulic Circuit Diagram 2169
Symbols Used in Hydraulic Circuit Diagram 2169
Hydraulic Circuit Diagram 2173
Hydraulic Circuit Diagram (at Boom RAISE Operation) 2175
Hydraulic Circuit Diagram (at Left Swing Operation) 2177
Hydraulic Circuit Diagram (at Boom RAISE and Left Swing Operation) 2179
Electrical Circuit Diagram 2181
Symbols Used in Electric Circuit Diagram 2181
Electrical Circuit Diagram (1/10) 2185
Electrical Circuit Diagram (2/10) 2187
Electrical Circuit Diagram (3/10) 2189
Electrical Circuit Diagram (4/10) 2191
Electrical Circuit Diagram (5/10) 2193
Electrical Circuit Diagram (6/10) 2195
Electrical Circuit Diagram (7/10) 2197
Electrical Circuit Diagram (8/10) 2199
Electrical Circuit Diagram (9/10) 2201
Electrical Circuit Diagram (10/10) 2203
Index 2205

DESCRIPTION:

Komatsu PC138E-11 Electric Hydraulic Excavator Shop Manual SEN06979-01 – PDF DOWNLOAD 

SERIAL NUMBERS 1 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some attachments and options shown in this shop manual are not available in some regions. If those are
required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• The drawings and photos shown in this shop manual are typical shapes, and they do not correspond to the
shapes of the applicable models in some cases.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details about the symbol marks shown on the machine monitor, see Structure and Function, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details about the switches of the machine monitor, see Testing and Adjusting, “Set and Operate
Machine Monitor”.
• For details of the switches, see “Operation and Maintenance Manual”.
Structure of Shop Manual
This shop manual contains the necessary technical information required for the service in the workshop. The
contents of the manual are sorted in the categories as follows for the practical use.
00 Index and Foreword
This section shows the index, forward, safety, and basic information.
01 Specification
This section shows the specifications of the machine.
10 Structure and Function
This section shows the structure and function of each component. “Structure and Function” not only shows the
detailed information to help more understanding of the structure of each device, it also can be used as a reference
material for Troubleshooting.
20 Standard Value Table
This section shows the standard value for the new machine and failure judgment criteria used in Testing and
Adjusting and Troubleshooting. This standard value table is used as the standard value during Testing and Adjusting,
and as the failure judgment during Troubleshooting.
30 Testing and Adjusting
This section shows the measurement tool required for Testing and Adjusting, measurement procedure, and adjustment
procedure for each part. For the standard value and failure judgment criteria for “Testing and Adjusting”,
see Standard Value Table.
40 Troubleshooting
This section shows the troubleshooting procedure for the defective part and remedy if a problem occurs. The
troubleshooting procedure is shown for each failure mode.
50 Disassembly and Assembly
This section gives information for the special tools, work procedures, and safety precautions necessary for removal,
installation, disassembly, and assembly of the components and parts. In addition, tightening torques,
quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section gives information about the maintenance standard for each component. The maintenance standard
shows the value of the judgment criteria value and remedy during the disassembly and maintenance.

IMAGES PREVIEW OF THE MANUAL:

S.V 22/12/24